Ice maker and ice storage compartment air flow system

ABSTRACT

A refrigerator has an air duct that brings a supply of chilled air to an air flow pathway that leads to an ice maker. A low profile impeller within the pathway forces the chilled air toward the ice maker. A curved vane guides the flow of air towards the ice maker. An impinger with a plurality of nozzles focuses the air flow from the impeller onto the ice maker.

FIELD OF THE INVENTION

The present invention relates generally to the field of household refrigerators. More specifically the invention relates to structures and methods for providing a flow of cold air to an ice maker and an ice storage compartment in a household refrigerator.

BACKGROUND OF THE INVENTION

Most household refrigerators include a freezer section for storing frozen foods, typically at temperatures near or below 0 degrees Fahrenheit, and a fresh food section for storing fresh foods at temperatures generally between 32 degrees Fahrenheit and about 40 degrees Fahrenheit. It is common to include ice makers and ice dispensers in household refrigerators. The ice dispensers permit ice to be dispensed from inside the refrigerator to outside the refrigerator without opening any of the doors. In a side-by-side refrigerator, where the freezer compartment and fresh food compartment are located side-by-side and divided by a vertical wall, or mullion, the ice maker and ice storage are generally provided in the freezer compartment and the ice is dispensed through the freezer door. In recent years it has become popular to provide so-called bottom mount refrigerators wherein the freezer compartment is located below the fresh food compartment, at the bottom of the refrigerator. In the bottom mount design it is preferable to provide the ice dispenser though a fresh food door so that the dispenser is at a convenient height. In these bottom mount refrigerators the ice maker and ice storage may be provided within a separate ice compartment located generally within or adjacent to, but insulated from, the fresh food compartment.

One way of freezing water to make ice within an ice compartment is to provide a supply of cold air from a chiller or compressor to an ice mold, using ducts and a fan. Generally speaking, the faster the air flow for a given temperature, the faster the ice mold can remove heat from the water to form ice. However, it is generally preferred to keep the air flow laminar, rather than turbulent in order to better control its flow and improve efficiency.

Generally the ice mold will be divided into sections that form separate ice pieces. The ice pieces are referred to as ice cubes, but are generally shaped with a portion of their outer surface that is cylindrical. A sensor, typically a thermistor, is attached to the ice mold to sense when the ice is ready to be harvested, based on the temperature of the ice mold at the sensor. If the portion of the mold nearest the temperature sensor cools faster than other portions, such that the ice cube or cubes nearest the sensor form first, the sensor may sense that it is time to harvest the ice cubes from the mold before all of the cubes are sufficiently formed. When this happens it results in an early harvest of the ice cubes from the ice mold.

Space can be at a premium within refrigerators, especially when the ice maker and ice storage are provided within the fresh food compartment. It is desirable to reduce the space used by the ice maker and air flow structures in order increase the amount of storage space in the fresh food compartment.

BRIEF SUMMARY OF THE INVENTION

According to an embodiment, the present invention is a refrigerator that has a cabinet and an air duct containing a supply of chilled air. A housing is mounted in the cabinet to receive chilled air from the air duct. The housing has an airflow pathway for providing air to an ice maker. An air moving device in the housing forces the chilled air towards the ice maker. A vane is located within the housing downstream from the air moving device to direct chilled air received from the air moving device towards a portion of the ice maker. The housing may include at least one insulated wall that defines a portion of an ice compartment containing the ice maker. The vane may have a curved surface to direct an air flow from the air moving device towards the portion of the ice maker in a generally laminar flow without substantial turbulence. The portion of the ice maker may be located remotely from a temperature sensor at the ice mold. An impinger may be located between the vane and the ice maker, and the impinger may include a plurality of nozzles for focusing an air flow from the air moving device on the ice maker. The ice maker may be mounted within the cabinet and an ice bin may be located on a door attached to the cabinet. An ice pathway may permit ice to move from the ice maker to the ice bin, and the ice pathway may permit air flow from the ice maker to the ice bin. The air moving device may be a low-profile radial-flow impeller that has a generally vertical axis of rotation.

According to another embodiment, the present invention is a refrigerator that includes an air flow pathway from an air duct containing chilled air to an ice maker. The air flow pathway includes an impeller for drawing chilled air from the air duct and impelling the chilled air towards the ice maker, wherein the impeller is a low-profile impeller. A vane may be located in the air flow pathway downstream from the impeller to guide the chilled air towards the ice maker in a desired flow pattern. The vane may direct chilled air towards a portion of the ice maker that is remote from a temperature sensor associated with the ice maker and away from a portion of the ice maker that is near to the temperature sensor. The vane may have a curved surface to direct air flow from the impeller towards the ice maker in a generally laminar flow. An impinger that has nozzles that focus air flow on the ice maker maybe located in the air flow pathway between the vane and the ice maker. An ice storage compartment may be provided in communication with the ice maker through an ice passageway, the ice passageway further providing a pathway for air to flow from the ice maker to the ice storage compartment. A return duct may be provided in communication between the ice storage compartment and the air duct. The ice maker may be mounted in an insulated ice compartment within the refrigerator cabinet and the ice storage compartment maybe mounted on a refrigerator door.

Another embodiment the present invention relates to a refrigerator of the type including an ice maker that freezes water into ice by forcing a flow of chilled air across the ice maker. The refrigerator includes a temperature sensor for sensing a temperature at a portion of the ice maker and a flow guidance member for guiding the flow of chilled air to the ice maker in a pattern such that an air flow rate at the portion of the ice maker is lower than other portions of the ice maker.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is an isometric view of a refrigerator according to an embodiment of the present invention.

FIG. 2 is an isometric view of the refrigerator of FIG. 1 with the doors to the fresh food compartment opened.

FIG. 3 is an exploded assembly view of an ice compartment and air flow system according to an embodiment of the present invention.

FIG. 4 is an isometric view of an impinger according to an embodiment of the present invention.

FIG. 5 is a cross-section view of a refrigerator showing the air flow to an ice maker and ice storage compartment according to an embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Although the present invention is described with respect to various embodiments, the present invention is not to be limited to the specific embodiments described herein. It is further to be understood that no single embodiment of the present invention need have all the structures or perform all the functions associated with any particular aspect or embodiment of the invention.

FIG. 1 shows a refrigerator 10 according to one embodiment of the present invention. The refrigerator 10 includes a cabinet 12 with attached fresh food doors 14 and freezer compartment door 16. It should be appreciated that while the fresh food doors 14 are shown as French doors, a single door could be used. Similarly, while the freezer door 16 is shown as a drawer type, it could be hingedly attached to the cabinet. The cabinet 12 and doors 14, 16 should be insulated. The refrigerator 10 includes chilling equipment (not shown) and an attachment (not shown) for connection to a power source. The refrigerator 10 also includes an inlet (not shown) for connection to a supply of water for use in making ice and dispensing fresh water.

One of the fresh food doors 14 is provided with a dispensing area 18 with an ice dispenser 20 for dispensing ice through the fresh food door 14, even when the fresh food door 14 is closed. The dispensing area 18 also preferably includes a water dispenser 22 for dispensing chilled drinking water through the fresh food door 14.

FIG. 2 shows the refrigerator 10 of FIG. 1 with the fresh food doors 14 opened. With the doors 14 opened, the fresh food compartment 24 can be seen. The fresh food compartment 24 may be provided with shelving and drawers (not shown) to support and display food and other items stored in the fresh food compartment 24. Air within the fresh food compartment is typically maintained below 40 degrees Fahrenheit, but above the freezing temperature of water (32 degrees Fahrenheit). Cold air can be provided to the fresh food compartment 24 through vent 26. Additional vents (not shown) connected to air ducts (not shown) that are in communication with the chilling equipment may also be provided. Return ducts (not shown) may also be provided to permit air flow through the fresh food compartment.

Ice compartment housing 28 is provided in the cabinet at an upper portion of the fresh food compartment 24. The ice compartment housing 28 is insulated and forms a portion of the top wall or roof of the fresh food compartment 24. The vent 26 is formed at the rear of the ice compartment housing 28. The ice compartment housing 28 may be made of molded plastic or similar refrigerator appropriate material. The ice compartment housing 28 encloses an ice compartment that includes the ice maker and an air flow system for chilling the ice maker (see FIG. 5) and the stored ice. The air flow system also provides cold air to the fresh food compartment 24. It may be desirable to include heaters within the housing 28 to prevent frost build up.

The front face of the ice compartment housing 28 includes an ice pathway opening 30 that leads from the exterior of the ice compartment housing 28 to the internal ice compartment. A door 32 that acts as cover may be provided to close the ice pathway opening 30 when the fresh food door 14 is opened. The ice compartment door 32 is normally biased into the closed position, but is mechanically opened by the fresh food door 14 interacting with button 34 when the fresh food door 14 is closed. Those of skill in the art will be aware of numerous structures for closing and opening the ice compartment door 32.

The ice pathway opening 30 aligns with a second opening 36 formed in the ice storage compartment housing 38 on the inner surface of one of the fresh food doors 14. A gasket 41, or similar seal, is provided to provide an air tight connection between the ice compartment housing 28 and the ice storage compartment housing 38 surrounding the openings 30 and 36 when the fresh food door 14 is closed. Therefore, when the fresh food door 14 is closed, an airtight ice pathway is provided from the ice compartment to the ice storage compartment. While the seal 41 is shown located on the ice storage compartment housing 38, it could be located on the ice compartment housing 28.

With continued reference to FIG. 2, the ice storage compartment housing 38 is provided on an inner portion of the fresh food door 14. An openable ice storage compartment cover 40 is provided on the ice storage compartment housing 38 to provide access to an ice storage compartment formed within the housing 38. The housing 38 and cover 40 should be insulated. It may be desirable to include heaters within the housing 38 and cover 40 to prevent frost build up. The cover 40 is shown as a hinged cover, but may be removable, and may be attached to an ice bin that is generally stored within the ice storage compartment to hold and store ice. A finger operated latch 42 provides a mechanism for selectively opening the cover 40.

Aperture 44 formed in the outer wall of the fresh food compartment 24 leads to a return duct for routing air from the ice storage compartment back to an evaporator or other cold air source (see FIG. 5).

FIG. 3 shows an exploded view of assembly 46 used to form an ice compartment and air flow system according to one embodiment of the present invention. The lower portion of the assembly 46 is formed by the ice compartment housing 28. The housing 28 may include an outer shell 48 and an upper layer 50. There may also be an additional layer or layers with various contours between the upper layer and the outer shell 48. Insulation may be provided between the outer shell 48 and the other layers.

An ice maker 52 is mounted to and supported by the housing 28. The ice maker 52 includes a control unit 54 with and internal motor and a test switch 56 for testing the ice maker 52. The ice maker 52 also includes an ice mold 58 in which ice is formed. Water is added to the ice mold 58 through fill cup 60. An impinger 62 is mounted to the rear side of the ice maker near the rear and bottom sides of the ice mold 58.

Details of the impinger 62 can be seen in FIG. 4. The impinger 62 includes mounts 64 for attachment to the ice maker 52. The impinger 62 is contoured to wrap around and match the contours of the ice mold 58. The impinger 62 includes a plurality of nozzles 66 which are formed by openings through the impinger 62. The nozzles 66 serve to direct and accelerate a flow of air directed towards the bottom side of the ice mold 58.

Returning to FIG. 3, the assembly 46 includes a low-profile radial-flow impeller 68. A scroll chamber 70 is formed around the impeller within the housing 28. A top plate 72 covers the impeller 68 within the scroll chamber 70 and provides an inlet opening 74 for air flow into the impeller 68. The impeller 68 rotates about a generally vertical axis. The scroll chamber 70 limits the flow of air out of the impeller 68 to either flow towards the ice maker via the ice maker air flow pathway 76 defined by guides 77 or through a fresh food compartment air flow pathway 78 (not visible in FIG. 3, see FIG. 5). A curved vane 80 is provided within the ice maker air flow pathway 76 between the impeller 68 and the ice maker 52. The rear of the housing 28 includes an air flow inlet pathway 82 defined by guide walls 84. A top cover 86 snaps on to the housing 28 to fully cover the air flow inlet pathway 82 and the impeller 68 and impeller scroll chamber 70.

A damper 88 is provided within the fresh food compartment pathway 78 (see FIG. 5) to permit and prevent air flow from the impeller 68 through the vent 26 via the fresh food compartment pathway 78. An electrical connection 90 is provided to attach the damper 88 to a power source.

A temperature sensor 89 is provided on the ice mold 58. In the embodiment shown the sensor 89 is located near the control unit 54 of the ice maker 52. The sensor 89 may be a thermistor. The sensor 89 is used to determine when the ice is ready for harvest. When the ice mold reaches a predetermined temperature, the control unit 54 harvests the ice from the mold 58. Typically harvest is accomplished by warming the mold 58, and rotating fingers (not shown) that extract the ice out of the mold 58. Other known mechanisms may be used for harvesting the ice.

FIG. 5 is a cross-sectional representation of a refrigerator that has the assembly 46 mounted at the top portion of the refrigerator cabinet 12, generally adjacent to or within the fresh food compartment 24. The fresh food compartment 24 is located above the freezer compartment 25. An insulated mullion 92 separates the fresh food compartment 24 from the freezer compartment 25. Cooling for the refrigerator 10 is provided by an evaporator 94 provided within or at least in thermal communication with a riser duct 96. A fan 98 moves air across the evaporator 94 and through the riser duct 96.

Air from the riser duct is supplied to the freezer compartment 25 through vent 100. Optionally the vent 100 may be provided with a damper to selectively open and close the vent 100.

The riser duct also supplies cold air to the inlet air flow pathway 82 at the rear of the housing 28. The cold air supplied to the inlet air flow pathway 82 flows through radial impeller scroll chamber 70. If the impeller is running, the cold air is impelled rapidly towards the ice maker 52. The vane 80 has a curved surface to guide the air flow towards the ice maker 52 so that the flow remains laminar or at least not significantly turbulent. The vane 80 also evens out the flow of air provided to the ice mold 58. According to one embodiment, the vane 80 directs a slightly greater supply of air towards an end of the ice mold that does not include the temperature sensor. Therefore, the ice cubes formed in the sections of the ice mold 58 nearest the temperature sensor connected to the ice mold 58 will tend to be ready for harvest later than the other sections, so that the ice maker will not attempt to harvest the ice before all of the cubes are ready. For example in FIG. 3, the temperature sensor 89 is located near the control unit 54. The vane 80 is contoured to guide a little less air to that portion of the mold 58 that is near the sensor 89. Therefore, it can be assured that if the mold near the sensor 89 has reached the desired temperature, the rest of the mold has reached that temperature, and the ice in all of the mold 58 is ready for harvest.

Air flows from the ice maker air flow pathway 76 and the vane 80 into the impinger 62. The nozzles 66 of the impinger 62 accelerate and focus the air flow on the appropriate portions of the ice mold 58 to facilitate heat removal from water with the ice mold 58.

When the ice is harvested from the ice mold 58, it drops through ice pathway openings 30 and 36 into an ice storage compartment 102 within the door 14. An ice bin 104 is provided within the ice storage compartment 102. Ice cubes are stored within the ice bin 104. The ice bin 104 is provided with a breaker bar or auger (not shown) to impartment movement to the stored ice for dispensing and to prevent ice bridging. The bin 104 is in operable communication with the ice dispenser 20 to dispense ice to the dispensing area 18 through the fresh food door 14.

After flowing through the impinger 62 and across the ice mold 58, the air flows through the ice pathway openings 30, 36 and around the ice bin 104. The ice bin 104 may be provided with vents (not shown) to permit some air flow through the ice in the ice bin 104. The ice storage compartment 102 includes an outlet (not shown) through the ice storage compartment housing 40 that corresponds with and cooperates with aperture 44 (see FIG. 2). Therefore, air flows through the ice storage compartment 102 to the return duct 106 and then back to the riser duct 96.

If the damper 88 is open, a portion of the cold air that moves through the scroll compartment 70 flows through the fresh food compartment air flow pathway 78 to the vent 26 and then into the fresh food compartment 24. If the damper is closed, a portion of the air flows through the return duct 106 and then back to the riser duct 96.

Although specific embodiments are described herein, the present invention contemplates numerous variations, options, and alternatives, including variations in the structure or configuration of the refrigerator, and variations in the type of material used. The present invention is not to be limited to the specific embodiments described herein or combinations of the specific embodiments described. 

1. A refrigerator comprising: a cabinet; an air duct in the cabinet containing a supply of chilled air; a housing mounted in the cabinet to receive chilled air from the air duct, the housing having an airflow pathway for providing air to an ice maker; an air moving device in the housing for forcing the chilled air towards the ice maker; and a vane within the housing down stream from the air moving device to direct chilled air received from the air moving device towards a portion of the ice maker.
 2. The refrigerator of claim 1 wherein the housing includes at least one insulated wall that defines a portion of an ice compartment containing the ice maker.
 3. The refrigerator of claim 2, wherein the at least one insulated wall insulates the ice compartment from a fresh food compartment that is maintained at a temperature above 32 degrees Fahrenheit.
 4. The refrigerator of claim 1, wherein the vane has a curved surface to direct an air flow from the air moving device towards the portion of the ice maker in a generally laminar flow.
 5. The refrigerator of claim 1, wherein the vane directs an air flow from the air movement device towards the portion of the ice maker without substantial turbulence.
 6. The refrigerator of claim 1, wherein the portion of the ice maker is located remotely from a temperature sensor at the ice mold.
 7. The refrigerator of claim 1, further comprising an impinger between the vane and the ice maker.
 8. The refrigerator of claim 7, wherein the impinger comprises a plurality of nozzles for focusing an air flow from the air moving device on the ice maker.
 9. The refrigerator of claim 1, wherein: the ice maker is mounted within the cabinet and an ice bin is located on a door attached to the cabinet; an ice pathway permits ice to move from the ice maker to the ice bin; and the ice pathway permits air flow from the ice maker to the ice bin.
 10. The refrigerator of claim 1, wherein the air moving device is a low-profile radial-flow impeller that has a generally vertical axis of rotation.
 11. A refrigerator comprising an air flow pathway from an air duct containing chilled air to an ice maker, the air flow pathway including an impeller for drawing chilled air from the air duct and impelling the chilled air towards the ice maker, wherein the impeller is a low-profile impeller.
 12. The refrigerator of claim 11, wherein a vane is located in the air flow pathway downstream from the impeller to guide the chilled air towards the ice maker in a desired flow pattern.
 13. The refrigerator of claim 12, wherein an impinger is located in the air flow pathway between the vane and the ice maker, the impinger comprising nozzles that focus air flow on the ice maker.
 14. The refrigerator of claim 12, wherein the vane directs chilled air towards a portion of the ice maker that is remote from a temperature sensor associated with the ice maker and away from a portion of the ice maker that is near to the temperature sensor.
 15. The refrigerator of claim 12, wherein the vane has a curved surface to direct air flow from the impeller towards the ice maker in a generally laminar flow.
 16. The refrigerator of claim 11, further comprising an ice storage compartment in communication to the ice maker through an ice passageway, the ice passageway further providing a pathway for air flow from the ice maker to the ice storage compartment.
 17. The refrigerator of claim 16, further comprising a return duct in communication between the ice storage compartment and the air duct.
 18. The refrigerator of claim 17, wherein the ice maker is mounted in an insulated ice compartment within the refrigerator cabinet and the ice storage compartment is mounted on a refrigerator door.
 19. A refrigerator of the type including an ice maker that freezes water into ice by forcing a flow of chilled air across the ice maker, the refrigerator comprising: a temperature sensor located at a portion of the ice maker; and a flow guidance member located in the flow of chilled air upstream from the ice maker such that an air flow rate at the portion of the ice maker where the temperature sensor is located is lower than other portions of the ice maker.
 20. The refrigerator of claim 19, wherein the temperature sensor is a thermistor. 